UV-Curable Powder Resin Multiphase Structure
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Solution Overview
Problem
Traditional UV-curable resins, both liquid and powder, face limitations such as high production costs, environmental impact due to solvent use, and unsatisfactory mechanical and chemical resistance in powder coatings, while also lacking versatility in application.
Innovation Solution
A multi-phase structured UV-curable powder coating resin is developed by combining emulsified liquid UV resin with a solid UV resin through phase transition, eliminating solvents and enhancing properties like impact and chemical resistance, allowing for a wide range of applications including heat-sensitive substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If liquid UV resin is used, then good leveling properties and mechanical properties are achieved, but solvent loss and environmental impact occur
Solution Approach 1:
The patent changes the physical state parameter of UV resin from liquid to powder form, eliminating the need for solvents while maintaining the resin's curable properties. This transformation allows the resin to be applied as powder without requiring diluting solvents, thus preventing solvent loss and environmental pollution while preserving mechanical properties through the UV curing mechanism.
Solution Approach 2:
The patent creates a composite powder coating system that combines UV-curable resin particles with appropriate additives and modifiers. This composite structure enables the powder to exhibit both the mechanical properties of liquid UV resins and the application advantages of powder coatings, achieving a balance between performance and environmental friendliness.
2Object-generated harmful factors
If solid UV resin powder coating is used, then environmental friendliness is improved, but leveling properties and mechanical properties deteriorate
Solution Approach 1:
The patent modifies the particle size, surface characteristics, and composition parameters of the solid UV resin powder to improve its flow, leveling, and adhesion properties. By controlling particle morphology and surface energy, the powder achieves better film formation and mechanical properties while maintaining its environmentally friendly powder form.
3Object-generated harmful factors
If traditional powder coating process is used, then solvent-free application is achieved, but curing temperature requirements increase
Solution Approach 1:
The patent replaces the thermal curing mechanism with a photopolymerization mechanism initiated by UV light. This substitution eliminates the need for high-temperature oven curing, allowing the powder coating to cure at lower temperatures through UV irradiation, thus reducing energy consumption and enabling application on heat-sensitive substrates.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting resin offers excellent impact and chemical resistance, can be cured at low temperatures, and produces transparent or opaque coatings with exceptional properties, suitable for various substrates, while being environmentally friendly and solvent-free.
Implementation Method 1
the liquid UV resin and the solid UV resin form a shell-core structure through phase transition achieved by melting, dispersing, cooling, and coating
Implementation Method 2
obtaining an emulsion of a liquid UV resin by heating the liquid UV resin and an emulsifier, dispersing and adding deionized water for emulsification
Implementation Method 3
melting and dispersing a solid UV resin, a phase change agent, an emulsifier, and the deionized water until fully molten and homogeneously dispersed
Implementation Method 4
press filtering the suspension of the UV-curable powder coating resin to obtain a filter cake
Implementation Method 5
drying and classifying the filter cake to obtain the multi-phase structured UV-curable powder coating resin
Data Source
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AI summary
The present invention provides a multi-phase structured UV-curable powder coating resin and a preparation method thereof, comprising (1) obtaining an emulsion of a liquid UV resin by heating the liquid UV resin and an emulsifier, dispersing, and adding deionized water for emulsification; (2) melting and dispersing a solid UV resin, a phase change agent, an emulsifier, and deionized water; adding the emulsion of the liquid UV resin with stirring to thoroughly mix; temperature is lowered during the stirring to obtain a suspension; (3) press filtering the suspension of the UV-curable powder coating resin to obtain a filter cake; (4) drying and classifying the filter cake to obtain the multi-phase structured UV-curable powder coating resin. The multi-phase structured UV-curable powder coating resin is prepared from the aforementioned method. The present disclosure has the properties of both the liquid UV resin and the solid UV resin and can be sprayed as a powder coating. It can be used in a wide range of applications and is environmentally friendly.